UTILEV UT13PTE User manual

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Part No. 76002086Part No. 76002086
1.31.3––2.0t 3-Wheel Battery Counte2.0t 3-Wheel Battery Counterbalanced Forklift Trbalanced Forklift Truckruck
Service ManualService Manual
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The Service Manuals are updated on a regular basis, but may not reflect recent designThe Service Manuals are updated on a regular basis, but may not reflect recent design
changes to the product. Updated technical service information may be available from yourchanges to the product. Updated technical service information may be available from your
local authorized UTILEV® distributor. Service Manuals provide general local authorized UTILEV® distributor. Service Manuals provide general guidelines forguidelines for
maintenance and service and are intended for use by trained and experienced technicians.maintenance and service and are intended for use by trained and experienced technicians.
Failure to properly maintain equipment or to follow instructions contained in the ServiceFailure to properly maintain equipment or to follow instructions contained in the Service
Manual could result in damage to the products, personal injury, property damage or death.Manual could result in damage to the products, personal injury, property damage or death.
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May 2013May 2013
ForewordForeword
This manual covers the components, operation, and servicing of the 1.3t-2.0tThis manual covers the components, operation, and servicing of the 1.3t-2.0t
3 wheel electric forklift truck.3 wheel electric forklift truck.
To ensure safe operation of this truck, it is important to read and understand theTo ensure safe operation of this truck, it is important to read and understand the
contents of this manual.contents of this manual.
Only qualified service personnel should perform maintenance on this truck.Only qualified service personnel should perform maintenance on this truck.
Product specifications in this manual may vary from your actual truck due toProduct specifications in this manual may vary from your actual truck due to
periodic improvements in design.periodic improvements in design.
Please contact your sales agent if you have any questions or commentsPlease contact your sales agent if you have any questions or comments
regarding this manual.regarding this manual.
This electric three-wheel forklift truck has passed the requirements for and is approved for operation inThis electric three-wheel forklift truck has passed the requirements for and is approved for operation in
countries adhering to CE regulations.countries adhering to CE regulations.
Model Model Driven Driven controllercontroller PumpPump
controllercontroller
Rated capacity(t)/ LoadRated capacity(t)/ Load
Center(mm)Center(mm)
UT13PTEUT13PTE CURTIS CURTIS 1234×2 1234×2 CURTIS CURTIS 12341234 1.3 / 5001.3 / 500
UT15PTEUT15PTE CURTIS CURTIS 1234×2 1234×2 CURTIS CURTIS 12341234 1.5 / 5001.5 / 500
UT16PTEUT16PTE CURTIS CURTIS 1234×2 1234×2 CURTIS CURTIS 12341234 1.6 / 5001.6 / 500
UT18PTEUT18PTE CURTIS CURTIS 1234×2 1234×2 CURTIS CURTIS 12341234 1.8 / 5001.8 / 500
UT20PTEUT20PTE CURTIS CURTIS 1234×2 1234×2 CURTIS CURTIS 12341234 2.0 / 5002.0 / 500
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ContentsContents
ForewordForeword
1 1 Drive Drive System System ................................................................................................................................................................................................. ......... 11
Gearbox ............................................................................................................... 1Gearbox ............................................................................................................... 1
2 2 Steering Steering System System ........................................................................................................................................................................................... ..... 44
Steering device .................................................................................................... 4Steering device .................................................................................................... 4
Steering axle ........................................................................................................ 5Steering axle ........................................................................................................ 5
3 3 Braking Braking System System ........................................................................................................................................................................................... ....... 77
Brake master cylinder .......................................................................................... 7Brake master cylinder .......................................................................................... 7
Hand brake .......................................................................................................... 8Hand brake .......................................................................................................... 8
4 4 Hydraulic Hydraulic System System .......................................................................................................................................................................................... .. 99
Main oil pump ...................................................................................................... 9Main oil pump ...................................................................................................... 9
Multi-way valve .................................................................................................. 10Multi-way valve .................................................................................................. 10
Pressure adjustment of main Pressure adjustment of main safety valve safety valve .............................................................................................................. ...... 1111
Hydraulic schematic diagram ............................................................................ 12Hydraulic schematic diagram ............................................................................ 12
5 5 Lifting Lifting System System ............................................................................................................................................................................................. ....... 1313
Mast................................................................................................................... 14Mast................................................................................................................... 14
Lift cylinder ........................................................................................................ 15Lift cylinder ........................................................................................................ 15
Tilt cylinder ........................................................................................................ 16Tilt cylinder ........................................................................................................ 16
6 6 Electrical Electrical System System .......................................................................................................................................................................... .............. 1717
Controller ........................................................................................................... 17Controller ........................................................................................................... 17
Circuit diagram .................................................................................................. 23Circuit diagram .................................................................................................. 23
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11
1 1 Drive Drive SystemSystem
The drive system adopts a dual-motor front wheel drive, wherein the left and right drive wheelsThe drive system adopts a dual-motor front wheel drive, wherein the left and right drive wheels
are driven independently by different motors, the rotation speed of the left and right motors isare driven independently by different motors, the rotation speed of the left and right motors is
controlled controlled by the reby the rear wheel stear wheel steering anering angle, and egle, and each motor ach motor is connected is connected to the to the gearbox, brgearbox, brakes,akes,
solid tires, rims solid tires, rims and other components.and other components.
The reduction gearbox is a double reduction system with a compact structure, comprising aThe reduction gearbox is a double reduction system with a compact structure, comprising a
first-stage cylindricafirst-stage cylindrical helical gear l helical gear set and set and a second-stage planetary final drive.a second-stage planetary final drive.
The brakes are maintenance-free, wet disc brakes.The brakes are maintenance-free, wet disc brakes.
Failure Failure Possible Possible Cause Cause RemedyRemedy
Loud impact sound whenLoud impact sound when
travelling and changingtravelling and changing
directiondirection
Excessive Excessive gear gear backlash backlash AdjustAdjust
Excessive Excessive gear gear wear wear ReplaceReplace
Gear noise when travellingGear noise when travelling
Gearbox Gearbox oil oil level level too too low low TTop op up up gear gear oiloil
Excessive Excessive gear gear backlash backlash AdjustAdjust
Excessive Excessive gear gear wear wear ReplaceReplace
GearboxGearbox
Technical parametersTechnical parameters
Item ParameterItem Parameter
Weight Weight (without (without oil) oil) 31 31 kgkg
Oil Oil capacity capacity 0.35 0.35 LL
Oil Oil type type AATF TF DEXRON DEXRON IIII
Foot brakeFoot brake
Brake fluidBrake fluid
Operating Operating pressure pressure 60-80 60-80 barbar
Normal Normal pressure pressure (maximum (maximum continuous) continuous) 80 80 barbar
Maximum Maximum pressure pressure 100 100 barbar
Hydraulic cylinder brake fluid volume (underHydraulic cylinder brake fluid volume (under
normal conditions)normal conditions) 1.71 cm1.71 cm33
Hydraulic cylinder brake fluid volume (underHydraulic cylinder brake fluid volume (under
maximum wear conditions)maximum wear conditions) 3.71 cm3.71 cm33
Hand brakeHand brake
Hand Hand brake brake lever lever pulling pulling force force 100 100 NN
Stroke Stroke 6 6 mmmm
Wear Wear limit limit stroke stroke 13 13 mmmm
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StructureStructure
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The brake rocker arm has three holesThe brake rocker arm has three holes
–– Air bleed plAir bleed plug: after addug: after adding brake fluiding brake fluid, loosen the b, loosen the bleed plug to leed plug to expel any trexpel any trapped airapped air..
–– Hand brake cable connection head: connection head has a wear limit of 13 mm. ReplaceHand brake cable connection head: connection head has a wear limit of 13 mm. Replace
connection head once this limit is exceeded.connection head once this limit is exceeded.
–– Brake wheel cylinder inlet port: replace in the event of Brake wheel cylinder inlet port: replace in the event of brake wheel cylinder leakagebrake wheel cylinder leakage..
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44
2 2 Steering Steering SystemSystem
The steering system consists of the steering device and the The steering system consists of the steering device and the steering axle.steering axle.
Steering deviceSteering device
The steering device consists of the steering wheel, upper shaft assembly, universal joint, lowerThe steering device consists of the steering wheel, upper shaft assembly, universal joint, lower
shaft assembly, bearings, snap rings, steering tube, steering gear, priority valve, clamping lever,shaft assembly, bearings, snap rings, steering tube, steering gear, priority valve, clamping lever,
hydraulic switch and other components. The steering wheel forward/backward tilt angle can behydraulic switch and other components. The steering wheel forward/backward tilt angle can be
adjusted according to need. See Figure 2-2.adjusted according to need. See Figure 2-2.
1. 1. Steering Steering wheel wheel 3. 3. Upper Upper shaft shaft assy assy 8. 8. Universal Universal joint joint 10. 10. Lower Lower shaft shaft assyassy
12. 12. Bearing Bearing 13. 13. Snap Snap ring ring 14. 14. Steering Steering tube tube 17. 17. Steering Steering geargear
18. 18. Priority Priority valve valve 19. 19. Clamping Clamping bolt bolt 22. 22. Clamping Clamping lever lever 26. 26. Hydraulic Hydraulic switchswitch
Figure Figure 2-2 2-2 Steering Steering devicedevice
Steering wheelSteering wheel
in central positionin central position
Rotation in direction BRotation in direction B
Rotation in direction CRotation in direction C
Locked positionLocked position
Released positionReleased position
A-A A-A rotationrotation
6° fwd tilt6° fwd tilt
6° bwd tilt6° bwd tilt
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Steering axleSteering axle
Italian-madItalian-made steering axle with e steering axle with a compact structure, see a compact structure, see Figure 2-3.Figure 2-3.
1. 1. Fastening Fastening spindle spindle 2. 2. Bracket Bracket 3. 3. Nut Nut 4. 4. ScrewScrew
5. 5. Washer Washer 6. 6. Check Check nut nut 7. 7. Gasket Gasket 8. 8. Adjuster Adjuster nutnut
9. 9. Seal Seal ring ring 10. 10. Bearing Bearing 111. 1. Rack Rack 12. 12. Seal Seal ringring
13. 13. Guide Guide sleeve sleeve 14. 14. Seal Seal ring ring 15. 15. Cylinder Cylinder body body 16. 16. Seal Seal ringring
17. 17. Cylinder Cylinder cap cap 18. 18. Axle Axle body body 19. 19. Bearing Bearing 20. 20. Seal Seal ringring
21. 21. Gear Gear shaft shaft 22. 22. Steering Steering axle axle spindle spindle 23. 23. Pin Pin 24. 24. GasketGasket
25. 25. Seal Seal ring ring 26. 26. Bearing Bearing 27. 27. Steered Steered wheel wheel hub hub 28. 28. BearingBearing
29. 29. Washer Washer 30. 30. Cotter Cotter pin pin 31. 31. Nut Nut 32. 32. Hub Hub capcap
33. Plug33. Plug
Figure 2-3 Steering axleFigure 2-3 Steering axle
The axle body (18) is fixed to the rear of the vehicle frame. Forces acting on it from thThe axle body (18) is fixed to the rear of the vehicle frame. Forces acting on it from the grounde ground
are carried by the support bearings (10,19). The adjuster nut (8) is used to adjust theare carried by the support bearings (10,19). The adjuster nut (8) is used to adjust the
preloadpreloadof the bearings (10,19). The cylinder body (15) is connected to the axle body (18). Theof the bearings (10,19). The cylinder body (15) is connected to the axle body (18). The
end sections of the rack (11) acts like pistons; when hydraulic oil from the priority valve flowsend sections of the rack (11) acts like pistons; when hydraulic oil from the priority valve flows
towards the cylinder body (15), it pushes the rack (11) to the left or to the right. The rack (11)towards the cylinder body (15), it pushes the rack (11) to the left or to the right. The rack (11)
engages with the gear shaft (21), which rotates the steered wheel left or right and turns theengages with the gear shaft (21), which rotates the steered wheel left or right and turns the
vehicle, with a maximum steering angle of 85° vehicle, with a maximum steering angle of 85° in both directions.in both directions.
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Precautions for use:Precautions for use:
In the event of oil leakage from the cylinder body, check and replace the seal rings (12,14,In the event of oil leakage from the cylinder body, check and replace the seal rings (12,14,
16). Also check the guide sleeve and 16). Also check the guide sleeve and cylinder body for damage.cylinder body for damage.
Periodically check the bearings (10,19) and their seal rings (9,20), and replace promptly ifPeriodically check the bearings (10,19) and their seal rings (9,20), and replace promptly if
damaged. Also change grease on a regular basis.damaged. Also change grease on a regular basis.
Periodically check the bearings (26, 28), and their seal ring (25), and replace promptly ifPeriodically check the bearings (26, 28), and their seal ring (25), and replace promptly if
damaged. Also change grease on a regular basis;damaged. Also change grease on a regular basis;
Adjusting the Adjusting the preload of preload of the sthe steered wheel teered wheel hub hub bearingbearings: s: remove the remove the counterweigcounterweight ht and itsand its
cover panel, then jack up the rear of the frame with an automotive jack so that the wheel iscover panel, then jack up the rear of the frame with an automotive jack so that the wheel is
off the ground. Tighten nut (3) until the steered wheel hub cannot be moved by hand, thenoff the ground. Tighten nut (3) until the steered wheel hub cannot be moved by hand, then
rotate it 1/6 to rotate it 1/6 to 1/4 turn in 1/4 turn in the opposite direction.the opposite direction.
Adjusting the preload of the support bearings (10,19): Adjusting the preload of the support bearings (10,19): Remove counterweigRemove counterweight and its coverht and its cover
panel, then jack up the rear of the frame. Tighten nut (8) until the steering spindle cannot bepanel, then jack up the rear of the frame. Tighten nut (8) until the steering spindle cannot be
moved by hand, then rotate nut (8) 1/6 moved by hand, then rotate nut (8) 1/6 to 1/4 turn in to 1/4 turn in the opposite direction.the opposite direction.
Problem Problem Cause Cause Analysis Analysis RemedyRemedy
Steering wheel will not turnSteering wheel will not turn
Pump Pump damaged damaged or or faulty faulty ReplaceReplace
Clogged or damaged priority valveClogged or damaged priority valve Flush orFlush or
replacereplace
Hose or connector damaged or pipe blockedHose or connector damaged or pipe blocked Replace orReplace or
flushflush
Steering is hardSteering is hard
Diverter valve pressure too lowDiverter valve pressure too low AdjustAdjust
pressurepressure
Air in the oil line Air in the oil line Bleed off airBleed off air
Steering gear fails to centre, positioning springSteering gear fails to centre, positioning spring
broken or weakbroken or weak
ReplaceReplace
springspring
Excessive leakage inside steering cylinderExcessive leakage inside steering cylinder Check pistonCheck piston
sealseal
Abnormal noiseAbnormal noise
Low Low oil oil tank tank level level Add Add oiloil
Damaged Damaged steering steering gear gear shaft shaft rack rack ReplaceReplace
Damaged Damaged wheel wheel bearing bearing or or support support bearing bearing ReplaceReplace
Inadequate Inadequate lubrication lubrication Add Add greasegrease
Clogged suction pipe or oil filterClogged suction pipe or oil filter Flush orFlush or
replacereplace
Oil leakOil leak
Defective steering cylinder seal ring or damagedDefective steering cylinder seal ring or damaged
pipe or connectorpipe or connector ReplaceReplace
Damaged wheel hub bearing or support bearing orDamaged wheel hub bearing or support bearing or
seal ringseal ring
Replace sealReplace seal
ringring
Steering angles of left andSteering angles of left and
right drive wheels (frontright drive wheels (front
wheels) do not matchwheels) do not match
Controller Controller parameters parameters incorrect incorrect AdjustAdjust
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